Productivity Knowledge Base: Avoiding rework
|The costs of rework
often go well beyond simply "doing the job times two." These
costs include doing the original work, undoing that work, doing that
work again, expediting parts and materials, handling wasted materials,
reassigning workers, disturbing other finished work, coordinating with
other trades, adding overtime to make up for schedule delays, and the
inability to do income-producing work.
On top of that, any equipment leased to do the work may need an extended lease. Think how much you pay to lease or rent lights, generators, lifts, cranes, and other such equipment. If you are using an outside testing firm and stretching their job out from three days to eight days, that’s an added cost, also.
Don’t forget the negative effect this has on the crews—nobody feels very motivated by doing a job over. Most folks, in the course of doing rework, have it in the back of their mind the thought, "This should not be happening. What a waste." And that thought is exactly right. Let’s bring it to the foreground of the mind, and look at how to prevent that waste.
To illustrate some principles, we can look at a job run by Foreman Bill. After we look at how Bill could have prevented rework, we’ll "zoom out" to see some effective strategies for preventing rework—strategies Bill’s company or yours can put into place. While Bill in this story isn’t real, your costs of rework very much are.
Bill’s crew ran power and communications wiring in a new office building. Unfortunately, the following things occurred:
Preventing Bill’s Project Rework
An examination of the three items above can teach us some valuable lessons. To see the lessons, identify the strategies, and learn how to correctly implement the strategies, talk to us about doing a seminar at your location.
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